CN116053090B - Circuit breaker conductor assembly and preparation method thereof - Google Patents
Circuit breaker conductor assembly and preparation method thereof Download PDFInfo
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- CN116053090B CN116053090B CN202310102892.5A CN202310102892A CN116053090B CN 116053090 B CN116053090 B CN 116053090B CN 202310102892 A CN202310102892 A CN 202310102892A CN 116053090 B CN116053090 B CN 116053090B
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Classifications
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- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01H—ELECTRIC SWITCHES; RELAYS; SELECTORS; EMERGENCY PROTECTIVE DEVICES
- H01H71/00—Details of the protective switches or relays covered by groups H01H73/00 - H01H83/00
- H01H71/08—Terminals; Connections
-
- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01H—ELECTRIC SWITCHES; RELAYS; SELECTORS; EMERGENCY PROTECTIVE DEVICES
- H01H69/00—Apparatus or processes for the manufacture of emergency protective devices
-
- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01R—ELECTRICALLY-CONDUCTIVE CONNECTIONS; STRUCTURAL ASSOCIATIONS OF A PLURALITY OF MUTUALLY-INSULATED ELECTRICAL CONNECTING ELEMENTS; COUPLING DEVICES; CURRENT COLLECTORS
- H01R43/00—Apparatus or processes specially adapted for manufacturing, assembling, maintaining, or repairing of line connectors or current collectors or for joining electric conductors
-
- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01R—ELECTRICALLY-CONDUCTIVE CONNECTIONS; STRUCTURAL ASSOCIATIONS OF A PLURALITY OF MUTUALLY-INSULATED ELECTRICAL CONNECTING ELEMENTS; COUPLING DEVICES; CURRENT COLLECTORS
- H01R43/00—Apparatus or processes specially adapted for manufacturing, assembling, maintaining, or repairing of line connectors or current collectors or for joining electric conductors
- H01R43/02—Apparatus or processes specially adapted for manufacturing, assembling, maintaining, or repairing of line connectors or current collectors or for joining electric conductors for soldered or welded connections
- H01R43/0214—Resistance welding
-
- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01R—ELECTRICALLY-CONDUCTIVE CONNECTIONS; STRUCTURAL ASSOCIATIONS OF A PLURALITY OF MUTUALLY-INSULATED ELECTRICAL CONNECTING ELEMENTS; COUPLING DEVICES; CURRENT COLLECTORS
- H01R43/00—Apparatus or processes specially adapted for manufacturing, assembling, maintaining, or repairing of line connectors or current collectors or for joining electric conductors
- H01R43/04—Apparatus or processes specially adapted for manufacturing, assembling, maintaining, or repairing of line connectors or current collectors or for joining electric conductors for forming connections by deformation, e.g. crimping tool
- H01R43/048—Crimping apparatus or processes
-
- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01R—ELECTRICALLY-CONDUCTIVE CONNECTIONS; STRUCTURAL ASSOCIATIONS OF A PLURALITY OF MUTUALLY-INSULATED ELECTRICAL CONNECTING ELEMENTS; COUPLING DEVICES; CURRENT COLLECTORS
- H01R43/00—Apparatus or processes specially adapted for manufacturing, assembling, maintaining, or repairing of line connectors or current collectors or for joining electric conductors
- H01R43/16—Apparatus or processes specially adapted for manufacturing, assembling, maintaining, or repairing of line connectors or current collectors or for joining electric conductors for manufacturing contact members, e.g. by punching and by bending
Landscapes
- Engineering & Computer Science (AREA)
- Manufacturing & Machinery (AREA)
- Fuses (AREA)
Abstract
The invention provides a circuit breaker conductor assembly and a preparation method thereof, wherein the conductor assembly comprises the following components: the high-temperature resistant insulating layer is arranged on the outer side of the conductive bar and is positioned in a contact area of the conductive bar and the transformer; the connecting plate is provided with a connecting part, the connecting part is arranged at the edge position close to the connecting plate, and one end of the conducting bar is connected with the connecting part in a metallurgical bonding mode or a riveting mode of the same material; the connecting piece is formed by compounding copper-aluminum composite materials on the side face, and the aluminum material end of the connecting piece is connected with the other end of the conducting bar in a metallurgical bonding mode or a riveting mode of the same material; and one end of the thermal element is connected with the copper material end of the connecting piece in a metallurgical bonding mode, and the other end of the thermal element is used for connecting thermal bimetal. The invention solves the problems that the welding between the conducting bar and the thermal element made of the aluminum material is not firm and the welding is easy to be removed, and simultaneously solves the problems that the insulating sleeve is not easy to be sleeved and replaced, the contact resistance is stable, and the working stability of the electric appliance can be improved.
Description
Technical Field
The invention relates to the technical field of piezoelectric devices, in particular to a circuit breaker conductor assembly and a preparation method thereof.
Background
And conducting assemblies such as conducting bars in the circuit breaker pass through the inner circles of the zero sequence transformers to obtain sampling signals, when overload current occurs to a certain extent in a protected circuit, the zero sequence transformers in the circuit breaker detect the signals, the circuit breaker trips rapidly, and a power supply is cut off to achieve the purpose of protecting the circuit.
In the process of assembling the circuit breaker, one end of the conducting bar assembly penetrates through the inner circle of the zero sequence transformer and is connected with the connecting plate, and finally, the circuit is externally connected; the other end of the conductive bar component is connected with the thermal element.
Because the inner circle area of the zero sequence transformer is limited, the electric gap between each phase is small, and interphase insulation is needed to avoid breakdown short circuit. However, when the circuit breaker is subjected to environmental, current and voltage changes in actual use, the insulation sleeve is easy to age, so that the phenomenon of higher temperature rise or interphase insulation damage occurs, the safe operation of the circuit breaker in a circuit is influenced, and the new insulation sleeve needs to be replaced in time. And because the zero sequence transformer penetrates through the connecting conductive assembly and the thermal element, the zero sequence transformer is very troublesome to replace. The conductive bar made of pure copper material is easy to soften and deform during high-temperature operation, and causes poor contact and unstable operation. The conducting bar made of the aluminum material is not easy to be firmly welded with the thermal element, and when the electric conduction is conducted, the contact resistance at the joint is easy to be high and the temperature is rapidly increased, so that the electric conduction assembly and the thermal element are subjected to desoldering.
Through retrieving, patent CN2013200470633 discloses a back conductor assembly, through changing the copper sheet length of three-phase four-wire, avoids its calorific capacity to exceed standard to slow down insulating sleeve ageing and improve copper bar high Wen Gongzuo and easily soften the deformation's condition, but the asymmetric setting of zero sequence transformer is passed to three-phase four-wire, causes the unstable operation of low voltage distribution system easily.
The application publication No. CN104505270A discloses a static contact of a circuit breaker, which comprises a conducting plate and a contact welded on the conducting plate, wherein the conducting plate comprises a welding section and a connecting section connected with the welding section, the contact is welded on the welding section, and the welding section and the connecting section are conductors with different materials. But this patent still has the following problems: the copper welding section of the conducting plate and the aluminum material end are compounded in a welding mode, so that the problems of unstable contact resistance and unstable welding of copper and aluminum exist.
There is an urgent need for a conductor assembly of a circuit breaker and a preparation method thereof, so as to solve at least one of the problems that the existing circuit breaker copper conductor bar is inconvenient to replace an insulating sleeve, high Wen Gongzuo is easy to soften and deform, aluminum conductor bar and a thermal element are easy to be unwelded, high-priced copper consumption is large, and the like.
Disclosure of Invention
In view of the defects in the prior art, the invention aims to provide a circuit breaker conductor assembly and a preparation method thereof.
According to one aspect of the present invention, there is provided a circuit breaker conductor assembly comprising:
the high-temperature resistant insulating layer is arranged on the outer side of the conducting bar and is positioned in a contact area of the conducting bar and the transformer;
the connecting plate is provided with a connecting part, the connecting part is arranged at the edge position close to the connecting plate, and one end of the conducting bar is connected with the connecting part in a metallurgical bonding mode or a riveting mode of the same material;
the connecting piece is formed by compounding copper-aluminum composite materials on the side face, and the aluminum material end of the connecting piece is connected with the other end of the conducting bar in a metallurgical bonding mode or a riveting mode of the same material;
and one end of the thermal element is connected with the copper material end of the connecting piece in a metallurgical bonding mode, and the other end of the thermal element is used for connecting thermal bimetal.
Further, the shape of the connecting piece is L-shaped or V-shaped.
Further, the thermal element is made of any one of silicon bronze, red copper, brass, constantan, phosphor bronze and copper clad steel.
Further, when one end of the conductive bar is connected with the connecting part in a metallurgical bonding mode of the same material, the connecting part is a convex rib; when one end of the conducting bar is connected with the connecting part in a riveting mode, the connecting part is a through hole.
Further, the conducting bars are made of aluminum or aluminum alloy, the connecting plates are made of copper-aluminum composite materials, and the conducting bars and the connecting plates are connected at the connecting portions in an aluminum-aluminum metallurgical bonding mode or a riveting mode.
Further, the high temperature resistant insulating layer material comprises any one of epoxy resin, phenolic resin, organic silicon high temperature resistant paint, glass fiber sleeve, aminoplast, fluoroplastic, polyvinyl chloride insulating tape or sleeve.
According to another aspect of the present invention, there is provided a method for manufacturing the above-mentioned circuit breaker conductor assembly, the method comprising:
processing the plate into a connecting plate, and processing a connecting part at the near edge of the surface of the connecting plate;
punching a plate or a wire into a conductive bar;
after the side surfaces of the plates or the strips are compounded, bending, punching and forming are carried out to form a connecting piece;
punching the plate into a thermal element;
forming a high-temperature-resistant insulating layer on the outer side of the conducting bar, wherein the high-temperature-resistant insulating layer is positioned in a contact area of the conducting bar and the transformer;
connecting one end of the conductive bar with the connecting part in a metallurgical bonding mode or a riveting mode of the same material;
the other end of the conductive bar is connected with the aluminum material end of the connecting piece in a metallurgical bonding mode or a riveting mode of the same material;
and connecting the thermal element with the copper material end of the connecting piece in a resistance welding mode to obtain the circuit breaker conductor assembly.
Further, after the side surfaces of the plates or the strips are compounded, the plates or the strips are bent and punched into a shape, and the method comprises the following steps: and (3) compounding the side surfaces of the plates or strips into copper-aluminum composite connecting plates, and bending and punching the copper-aluminum composite connecting plates at the composite interface to form V-shaped or L-shaped plates.
Further, the metallurgical bonding mode or riveting mode of the same material is adopted to connect one end of the conductive bar with the connecting part, and the method comprises the following steps:
the connecting part is a convex rib, the conducting bar is made of aluminum or aluminum alloy, one end of the conducting bar is flattened, and the conducting bar is welded at the convex rib by adopting a laser welding or resistance welding mode, so that aluminum-aluminum combination of the conducting bar and the connecting plate is realized; or,
the connecting part is a through hole, the conducting bar is made of aluminum or aluminum alloy, and is riveted at the through hole in a riveting mode, so that aluminum-aluminum combination of the conducting bar and the connecting plate is realized.
Further, the metallurgical bonding mode or riveting mode of the same material is adopted to connect the other end of the conductive bar with the aluminum material end of the connecting piece, and the metallurgical bonding mode or riveting mode comprises the following steps: flattening the other end of the conductive bar, and connecting the other end of the conductive bar to the aluminum material end of the connecting piece in a laser welding or resistance welding mode or riveting mode to realize aluminum-aluminum combination of the conductive bar and the connecting piece.
Compared with the prior art, the invention has at least one of the following beneficial effects:
1. according to the circuit breaker conductor assembly and the preparation method thereof, the aluminum material end of the connecting piece is connected with the conductive bar in a metallurgical bonding mode or a riveting mode of the same material through the connecting piece formed by compounding the copper-aluminum composite materials on the side face, and the copper material end of the connecting piece is connected with the thermal element in the metallurgical bonding mode, so that the aluminum conductive bar and the thermal element can be firmly connected; and through metallurgical bonding or riveting of the same material between the aluminum conducting bar and the connecting plate, copper and aluminum are prevented from being directly welded, the problem of unstable contact resistance at the copper-aluminum interface is solved, firm connection between the conducting bar and the connecting plate can be realized, and the contact resistance is stable, so that the working stability of an electric appliance is improved.
2. According to the circuit breaker conductor assembly and the preparation method thereof, the conductive bars are formed by pre-punching, and the high-temperature insulating layer is formed on the outer side of the conductive bars, so that the problem that the insulating sleeve is not easy to sleeve and replace can be effectively solved.
Drawings
Other features, objects and advantages of the present invention will become more apparent upon reading of the detailed description of non-limiting embodiments, given with reference to the accompanying drawings in which:
FIG. 1 is a schematic diagram of an embodiment of an electrical circuit breaker conductive assembly;
FIG. 2 is a schematic diagram illustrating a partial structure of a conductive component of an interrupt circuit according to an embodiment of the present invention;
FIG. 3 is a schematic diagram of a composite interface structure of a lateral composite connector before punching and bending according to an embodiment of the present invention, wherein the composite interface is a toothed line;
FIG. 4 is a schematic view of a composite interface structure of a lateral composite connector before punching and bending, wherein the composite interface is a serrated surface;
FIG. 5 is a schematic diagram of a composite interface structure of a lateral composite connector before punching and bending in accordance with an embodiment of the present invention, wherein the composite interface is a wavy surface;
FIG. 6 is a schematic diagram of a composite interface structure of a lateral composite connector before punching and bending, wherein the composite interface is an inclined plane;
FIG. 7 is a schematic diagram of an embodiment of an electrical circuit breaker conductive assembly;
FIG. 8 is a schematic diagram illustrating a partial structure of a conductive component of an interrupt circuit according to an embodiment of the present invention;
in the figure: 1-connecting plate, 2-conducting bar, 3-connecting piece, 4-heat element, 5-connecting part, 6-aluminum material end, 7-copper material end, 8-aluminum surface, 9-high temperature resistant insulating layer, 10-mutual inductor and 11-rivet.
Detailed Description
The present invention will be described in detail with reference to specific examples. The following examples will assist those skilled in the art in further understanding the present invention, but are not intended to limit the invention in any way. It should be noted that variations and modifications could be made by those skilled in the art without departing from the inventive concept. These are all within the scope of the present invention.
An embodiment of the present invention provides a circuit breaker conductor assembly, referring to fig. 1-2, comprising a conductor bar 2, a connection plate 1, a connection piece 3 and a thermal element 4, wherein: the outer side of the conductive bar 2 is provided with a high-temperature resistant insulating layer 9, and the high-temperature resistant insulating layer 9 is positioned in the contact area of the conductive bar 2 and the transformer 10; the connecting plate 1 is provided with a connecting part 5, and because the space in the circuit breaker is limited, the connecting part 5 is arranged at the edge position close to the connecting plate 1, the connecting plate and the like are prevented from being fixed by interference screws, and one end of the conducting bar 2 is connected with the connecting part 5 in a metallurgical bonding mode or a riveting mode of the same material; the connecting piece 3 is formed by side face composite copper-aluminum composite material, and an aluminum material end 6 of the connecting piece 3 is connected with the other end of the conductive bar 2 in a metallurgical bonding mode or a riveting mode of the same material; one end of the thermal element 4 is connected with the copper material end 7 of the connecting piece 3 in a metallurgical bonding mode, and the other end is used for connecting thermal bimetal.
According to the embodiment of the invention, the conductive bar 2 is pre-punched and formed, and the high-temperature resistant insulating layer 9 is formed on the outer side of the conductive bar 2, so that the problem that the insulating sleeve is not easy to sleeve and replace can be effectively solved. The aluminum material end of the connecting piece 3 is connected with the conductive bar 2 in a metallurgical bonding mode or a riveting mode of the same material, the copper material end of the connecting piece 3 is connected with the thermal element 4 in a metallurgical bonding mode, and the conductive bar 2 and the connecting plate 1, the conductive bar 2 and the connecting piece 3, and the connecting piece 3 and the thermal element 4 can be firmly connected through the metallurgical bonding or riveting of the same material between the conductive bar 2 and the connecting plate 1, and the contact resistance is stable, so that the working stability of an electric appliance is improved.
In the above embodiment, the material of the connecting piece 3 is a laterally composite copper-aluminum composite material, which means a material formed by laterally compositing copper and aluminum metal materials into a whole by any mode of cold rolling or hot rolling, warm rolling, compositing, extruding, die casting, and the like, and is punched and bent into a V shape or an L shape at an interface position, so as to form the L-shaped or V-shaped connecting piece 3. Because the internal space of the electric appliance is limited, and the positions of all parts in the electric appliance are limited, the connection of the parts and the connecting piece on the surface with larger area can be realized through the L-shaped or V-shaped connecting piece 3, so that the current carrying area is increased, and the resistance of the connecting part is reduced. Before punching and bending, the composite interface of the aluminum material end 6 and the copper material end 7 in the lateral composite copper-aluminum composite material is any one of a plane, a wave surface, an inclined plane or a serrated surface and an arc surface, and as shown in fig. 3-6, the composite interface in the forms can increase the connecting area of lateral composite at the interface, so that the bonding strength of the two materials at the composite interface is improved. The lateral composite copper-aluminum composite material comprises a copper material end 7 and an aluminum material end 6 which are sequentially arranged, wherein the copper material end 7 is made of any one of pure copper, red copper, oxygen-free copper, iron bronze, copper alloy and dispersion-reinforced copper alloy, and the aluminum material layer is made of pure aluminum or aluminum alloy.
The material of the thermal element 4 may be silicon bronze, or any one of red copper, brass, constantan, phosphor bronze, and copper clad steel, and when current flows into the thermal element 4 of these materials, heat is generated, so that the bimetal is deformed. The above embodiment adopts the lateral composite copper-aluminum composite material to respectively connect the conductive bar 2 and the thermal element 4, so as to avoid the problems of infirm and desoldering caused by the uneasy firm welding of copper-aluminum between the conductive bar 2 made of aluminum material and the thermal element 4 made of silicon bronze material and the like. The conductive component obtained in the mode has stable contact resistance at the joint, remarkably reduces the temperature rise of the electrical appliance, improves the high-temperature deformation resistance of the conductive component, avoids interphase breakdown short circuit caused by gap change between interphase and greatly improves the stability of the electrical appliance during operation.
In the above embodiment, the conductive bars 2 are formed by sheet punching. With continued reference to fig. 1-2, when one end of the conductive bar 2 is connected with the connecting portion 5 by adopting a metallurgical bonding mode of the same material, the connecting portion 5 is a convex rib, and the shape of the convex rib is any one of a straight line shape, a curved line shape and a dot shape; referring to fig. 7 to 8, when one end of the conductive bar 2 is connected to the connection part 5 by means of riveting, the connection part 5 is a through hole penetrating through the thickness direction of the connection plate 1 for subsequent riveting, and the rivet 11 passes through the through hole to realize the riveting. The metallurgical bonding mode and the riveting mode of the same material can realize firm connection between the elements of the conductive assembly.
In some embodiments, the conductive bars 2 are made of aluminum or aluminum alloy, the connecting plate 1 is made of copper-aluminum composite material, and the conductive bars 2 are connected with the connecting plate 1 at the connecting part 5 through an aluminum-aluminum metallurgical bonding mode or a riveting mode. Because copper and aluminum are not easy to be firmly welded and combined, the problem of infirm caused by copper-aluminum welding and combining can be effectively avoided by adopting a connecting mode of an aluminum-aluminum metallurgical combining mode. Moreover, compared with the copper connecting plate in the prior art, the connecting plate formed by the copper-aluminum composite material can remarkably reduce the consumption of noble metal copper.
According to the embodiment of the invention, the conventional copper conductive bars are replaced by the conductive bars 2 made of the aluminum materials with the same current carrying area, and the aluminum materials of the conductive bars 2 are connected with the aluminum surface 8 of the connecting plate 1 by the same material, so that the contact resistance of the conductive assembly is stable, and the purpose of reducing the use amount of noble metal copper and guaranteeing the use performance of an electrical appliance is realized. In addition, because the aluminum conductive bars are adopted, compared with the copper conductive bars adopted in the prior art, the noble metal copper consumption can be greatly reduced, and the production cost is obviously reduced.
In some embodiments, the high temperature resistant insulating layer 9 is formed by adopting a high temperature resistant insulating material, and the high temperature resistant insulating layer 9 material comprises any one of epoxy resin, phenolic resin, organosilicon high temperature resistant paint, glass fiber sleeve, aminoplast, fluoroplastic, polyvinyl chloride insulating tape or sleeve, and the materials have good temperature resistance and thermal stability, so that stable insulation is kept between the conductive bars 2 and the transformer 10, and the product stability of the leakage circuit breaker is ensured. Of course, in other embodiments, other kinds of high temperature resistant insulating layers 9 may be employed as long as the same functions as in the embodiments of the present invention can be achieved.
In other alternative embodiments, the conductive bars 2 may be wires, such as aluminum alloy wires, and the conductive bars 2 formed by using the wires may have the same technical effect as the conductive bars 2 formed by using the plate material, and will not be described in detail herein.
Another embodiment of the present invention provides a method for manufacturing the circuit breaker conductor assembly, referring to fig. 1-2 and fig. 7-8, the method includes:
s1, processing a plate into a connecting plate 1, and processing a connecting part 5 at the near edge of the surface of the connecting plate 1;
s2, punching a plate or a wire into a conductive bar 2;
s3, compounding the side surfaces of the plates or the strips, and bending, punching and forming to form a connecting piece 3;
s4, punching the plate into a thermal element 4;
s5, forming a high-temperature-resistant insulating layer 9 on the outer side of the conductive bar 2, wherein the high-temperature-resistant insulating layer 9 is positioned in a contact area of the conductive bar 2 and the transformer 10;
s6, connecting one end of the conductive bar 2 with the connecting part 5 in a metallurgical bonding mode or a riveting mode of the same material;
s7, connecting the other end of the conductive bar 2 with the aluminum material end 6 of the connecting piece 3 in a metallurgical bonding mode or a riveting mode of the same material;
and S8, connecting the thermal element 4 and the copper material end 7 of the connecting piece 3 by adopting a resistance welding mode to obtain the circuit breaker conductor assembly.
In some embodiments, after the side of the plate or the strip is compounded, the plate or the strip is bent and punched into a shape, including: and (3) compounding the side surfaces of the plates or strips into a copper-aluminum composite connecting plate 1, and bending and punching the copper-aluminum composite connecting plate at a composite interface to form a V shape or an L shape.
In some embodiments, the connecting of the one end of the conductive bar 2 and the connecting portion 5 by using the metallurgical bonding or riveting method of the same material includes:
the connecting part 5 is a convex rib, the material of the conducting bar 2 is aluminum or aluminum alloy, one end of the conducting bar 2 is flattened to increase the connecting area, so that the current carrying area is increased, the resistance is reduced, and the conducting bar 2 and the aluminum-aluminum combination of the connecting plate 1 are realized by welding the connecting part at the convex rib in a laser welding or resistance welding mode; or the connecting part 5 is a through hole, the conducting bar 2 is made of aluminum or aluminum alloy, and is riveted at the through hole by adopting a riveting mode, so that the aluminum-aluminum combination of the conducting bar 2 and the connecting plate 1 is realized.
In some embodiments, the metallurgical bonding or riveting mode of the same material is used to connect the other end of the conductive bar 2 with the aluminum material end 6 of the connector 3, including: flattening the other end of the conductive bar 2, and connecting the other end of the conductive bar 2 to the aluminum material end 6 of the connecting piece 3 by adopting a laser welding or resistance welding mode or adopting a riveting mode to realize aluminum-aluminum combination of the conductive bar 2 and the connecting piece 3.
The circuit breaker conductor assembly of the present invention and its method of preparation are further described in more detail in terms of examples.
Example 1
The preparation method of the circuit breaker conductor assembly provided by the embodiment comprises the following steps:
s1, firstly processing a Cu/Al plate into a Cu/Al connecting plate 1, and then processing 2 linear convex ribs along the near edge of the connecting plate 1, referring to FIG. 1;
s2, punching the pure aluminum wire into the pure aluminum conducting bar 2, wherein the obtained pure aluminum conducting bar 2 has the same current carrying density as a conventional pure copper conducting bar, and flattening one end of the conducting bar 2. The pure aluminum conducting bar 2 is bent, so that the conducting bar 2 can pass through the transformer 10 in the limited space of the circuit breaker, and other parts can be connected as conveniently as possible;
s3, spraying epoxy resin on the pure aluminum conductive bar 2, wherein the spraying position is shown in the position where the conductor assembly and the transformer 10 act in the figure 1, a high-temperature resistant insulating layer 9 is formed, the high-temperature resistant insulating layer 9 is positioned in the contact area of the conductive bar 2 and the transformer 10, and the dip-coating position is shown in the figure 1; the high-temperature resistant insulating layer 9 can insulate the contact area between the pure aluminum conductor bar 2 and the transformer 10, so that the phenomenon that the pure aluminum conductor bar 2 or the transformer 10 is burnt due to short circuit breakdown between the pure aluminum conductor bar 2 and the transformer 10 is avoided.
S4, compounding the side surfaces of the pure Cu plate and the pure Al plate into a copper-aluminum composite connecting piece 3, and punching and bending the copper-aluminum composite connecting piece into an L shape at a compound interface, referring to FIG. 2;
s5, punching the silicon bronze plate into a thermal element 4;
s6, placing flattened one end of the aluminum conductor bar 2 obtained in the S3 at the convex rib of the Cu/Al composite connecting plate 1, and then connecting one end of the conductor bar 2 with the connecting plate 1 by resistance welding to realize metallurgical bonding of the aluminum conductor bar 2 and the aluminum surface 8 of the connecting plate 1.
S7, connecting the other end of the aluminum conductive bar 2 obtained in the S3 with the aluminum material end 6 of the copper-aluminum side surface composite connecting piece 3 obtained in the S4 by laser welding to realize aluminum-aluminum metallurgical bonding;
and S8, performing resistance welding connection on the thermal element 4 obtained by the copper material ends 7 and S5 of the copper-aluminum side composite connecting piece 3 obtained by the S4 to obtain the circuit breaker conductive assembly.
The preparation method of the circuit breaker conductor assembly has the advantages that the steps are simple, the mass production is easy, the input cost is low, the produced conductive assembly adopts aluminum wires to replace copper conductive bars on the premise that the conductivity of the assembly is not reduced, and high-temperature resistant insulating materials are coated on the aluminum wires in a dip-coating mode, so that the consistency of the product quality is greatly improved, the consumption of noble metal copper is obviously reduced, the aluminum wires and the connecting plates adopt an aluminum-aluminum metallurgical bonding mode, and side composite copper-aluminum connecting pieces are adopted to respectively connect the aluminum wires and the thermal elements, so that the problems of unstable contact resistance and high-temperature softening deformation of pure copper due to the fact that aluminum-copper connecting welding is not firm are avoided; the circuit breaker manufactured by the conductive component has the electrical life equivalent to that of a conventional product, and the consumption of noble metal copper is reduced by 22 percent.
Example 2
The preparation method of the circuit breaker conductor assembly provided by the embodiment comprises the following steps:
s1, processing a Cu/Al plate into a Cu/Al connecting plate 1, and then processing a through hole along the near edge of the connecting plate 1 for subsequent riveting, wherein the FIG. 7 is referred to;
s2, punching the aluminum alloy wire into an aluminum alloy conducting bar 2, wherein the obtained aluminum alloy conducting bar 2 has the same current carrying density as a conventional pure copper conducting bar, and flattening one end of the conducting bar 2. The aluminum alloy conductor bar 2 is bent, so that the conductor bar 2 can pass through the transformer 10 in the limited space of the circuit breaker, and other parts can be connected as conveniently as possible;
s3, forming a high-temperature-resistant insulating layer 9 by adopting a powder dip-coating phenolic epoxy resin mode on the outer side of the aluminum alloy conductive bar 2, wherein the high-temperature-resistant insulating layer 9 is positioned in a contact area of the conductive bar 2 and the transformer 10, and the dip-coating position is shown in figure 7; the high-temperature resistant insulating layer 9 can insulate the contact area between the aluminum alloy conductor bar 2 and the transformer 10, so that the aluminum alloy conductor bar 2 or the transformer 10 is prevented from being burnt due to short circuit breakdown between the aluminum alloy conductor bar 2 and the transformer 10.
S4, compounding the side surfaces of the pure Cu plate and the pure Al plate into a copper-aluminum composite connecting piece 3, and punching and bending the copper-aluminum composite connecting piece into an L shape at a compound interface, referring to FIG. 8;
s5, punching the constantan plate into a thermal element 4;
s6, placing one flattened end of the aluminum alloy conductor bar 2 obtained in the S3 at a through hole of the Cu/Al composite connecting plate 1, then penetrating through the through hole on the connecting plate 1 by adopting an aluminum rivet 11, and riveting one end of the conductor bar 2 and the connecting plate 1 to realize aluminum-aluminum combination of the aluminum alloy conductor bar 2 and the connecting plate 1.
S7, riveting the other end of the aluminum conductive bar 2 obtained in the S3 with the aluminum material end 6 of the copper-aluminum side surface composite connecting piece 3 obtained in the S4 by adopting an aluminum rivet 11 to realize aluminum-aluminum combination;
and S8, performing resistance welding connection on the thermal element 4 obtained by the copper material ends 7 and S5 of the copper-aluminum side composite connecting piece 3 obtained by the S4 to obtain the circuit breaker conductive assembly.
The preparation method of the circuit breaker conductor assembly has the advantages that the steps are simple, the mass production is easy, the input cost is low, the produced conductive assembly adopts aluminum alloy conductive bars to replace copper conductive bars on the premise that the conductivity of the assembly is not reduced, and high-temperature resistant insulating materials are coated on the aluminum alloy conductive bars in a dip-coating mode, so that the consistency of product quality is greatly improved, the consumption of noble metal copper is obviously reduced, the aluminum alloy conductive bars and the connecting plates are connected with aluminum wires and thermal elements in a riveting combination mode by adopting side face composite copper-aluminum connecting pieces, the problems that aluminum-copper connection welding is not firm and easy to be detached, the contact resistance is unstable and pure copper is easy to soften and deform at high temperature are avoided, and compared with a conventional product, the product yield is improved by 20%; the circuit breaker manufactured by the conductive component has the electrical life equivalent to that of a conventional product, and the consumption of noble metal copper is reduced by 20 percent.
The foregoing describes specific embodiments of the present invention. It is to be understood that the invention is not limited to the particular embodiments described above, and that various changes and modifications may be made by one skilled in the art within the scope of the claims without affecting the spirit of the invention. The above-described preferred features may be used in any combination without collision.
Claims (9)
1. A circuit breaker conductor assembly comprising:
the high-temperature resistant insulating layer is arranged on the outer side of the conducting bar and is positioned in a contact area of the conducting bar and the transformer;
the connecting plate is provided with a connecting part, the connecting part is arranged at the edge position close to the connecting plate, and one end of the conducting bar is connected with the connecting part in a metallurgical bonding mode or a riveting mode of the same material;
the connecting piece is formed by compounding copper-aluminum composite materials on the side face, and the aluminum material end of the connecting piece is connected with the other end of the conducting bar in a metallurgical bonding mode or a riveting mode of the same material; the side surface composite copper-aluminum composite material is a material formed by laterally compositing copper and aluminum metal materials into a whole; the composite interface of the aluminum material end and the copper material end in the side composite copper-aluminum composite material is any one of a plane, a wavy surface, an inclined plane or a serrated surface and an arc surface; the shape of the connecting piece is L-shaped or V-shaped;
and one end of the thermal element is connected with the copper material end of the connecting piece in a metallurgical bonding mode, and the other end of the thermal element is used for connecting thermal bimetal.
2. The circuit breaker conductor assembly of claim 1 wherein the thermal element is any one of silicon bronze, copper, brass, constantan, phosphor bronze and copper clad steel.
3. The circuit breaker conductor assembly of claim 1 wherein the connection is a bead when one end of the conductor bar is connected to the connection by metallurgical bonding of the same material; when one end of the conducting bar is connected with the connecting part in a riveting mode, the connecting part is a through hole.
4. The circuit breaker conductor assembly of claim 1, wherein the conductive bars are made of aluminum or aluminum alloy, the connecting plates are made of copper-aluminum composite materials, and the conductive bars and the connecting plates are connected at the connecting parts in an aluminum-aluminum metallurgical bonding mode or a riveting mode.
5. The circuit breaker conductor assembly of claim 1, wherein the high temperature resistant insulating layer material comprises any one of epoxy-based resins, phenolic-based resins, silicone-based high temperature resistant lacquers, fiberglass-based bushings, aminoplasts, fluoroplastics, polyvinyl chloride-based insulating tapes, or bushings.
6. A method of making a circuit breaker conductor assembly of any of claims 1-5 comprising:
processing the plate into a connecting plate, and processing a connecting part at the near edge of the surface of the connecting plate;
punching a plate or a wire into a conductive bar;
after the side surfaces of the plates or the strips are compounded, bending, punching and forming are carried out to form a connecting piece;
punching the plate into a thermal element;
forming a high-temperature-resistant insulating layer on the outer side of the conducting bar, wherein the high-temperature-resistant insulating layer is positioned in a contact area of the conducting bar and the transformer;
connecting one end of the conductive bar with the connecting part in a metallurgical bonding mode or a riveting mode of the same material;
the other end of the conductive bar is connected with the aluminum material end of the connecting piece in a metallurgical bonding mode or a riveting mode of the same material;
and connecting the thermal element with the copper material end of the connecting piece in a resistance welding mode to obtain the circuit breaker conductor assembly.
7. The method of manufacturing a circuit breaker conductor assembly of claim 6, wherein the forming by bending and stamping after the side face of the plate or the strip is compounded comprises: and (3) compounding the side surfaces of the plates or strips into copper-aluminum composite connecting plates, and bending and punching the copper-aluminum composite connecting plates at the composite interface to form V-shaped or L-shaped plates.
8. The method for manufacturing a circuit breaker conductor assembly of claim 6, wherein the connecting one end of the conductive bar with the connecting portion by using a metallurgical bonding method or a riveting method of the same material comprises:
the connecting part is a convex rib, the conducting bar is made of aluminum or aluminum alloy, one end of the conducting bar is flattened, and the conducting bar is welded at the convex rib by adopting a laser welding or resistance welding mode, so that aluminum-aluminum combination of the conducting bar and the connecting plate is realized; or,
the connecting part is a through hole, the conducting bar is made of aluminum or aluminum alloy, and is riveted at the through hole in a riveting mode, so that aluminum-aluminum combination of the conducting bar and the connecting plate is realized.
9. The method for manufacturing a circuit breaker conductor assembly of claim 6, wherein the connecting the other end of the conductive bar and the aluminum material end of the connecting member by metallurgical bonding or riveting of the same material comprises: flattening the other end of the conductive bar, and connecting the other end of the conductive bar to the aluminum material end of the connecting piece in a laser welding or resistance welding mode or riveting mode to realize aluminum-aluminum combination of the conductive bar and the connecting piece.
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| Publication number | Priority date | Publication date | Assignee | Title |
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| CN201749978U (en) * | 2010-08-03 | 2011-02-16 | 宁波奉欣电力金具制造有限公司 | A copper-aluminum composite terminal |
| CN109427437A (en) * | 2017-08-31 | 2019-03-05 | 株洲中车时代电气股份有限公司 | A kind of Copper-Aluminum compound low-inductance bus and its manufacturing method |
| CN217134310U (en) * | 2021-12-31 | 2022-08-05 | 常熟开关制造有限公司(原常熟开关厂） | Thermal overload release of circuit breaker |
| CN217182116U (en) * | 2022-05-05 | 2022-08-12 | 温州宏丰特种材料有限公司 | Copper-aluminum composite connecting assembly of molded case circuit breaker |
| CN115440543A (en) * | 2022-09-16 | 2022-12-06 | 温州宏丰电工合金股份有限公司 | Electric leakage circuit breaker conductor assembly and preparation method thereof |
Family Cites Families (1)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| US6492037B2 (en) * | 1997-07-11 | 2002-12-10 | Kabushiki Kaisha Toshiba | Joined structure of dissimilar metallic materials |
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Patent Citations (5)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| CN201749978U (en) * | 2010-08-03 | 2011-02-16 | 宁波奉欣电力金具制造有限公司 | A copper-aluminum composite terminal |
| CN109427437A (en) * | 2017-08-31 | 2019-03-05 | 株洲中车时代电气股份有限公司 | A kind of Copper-Aluminum compound low-inductance bus and its manufacturing method |
| CN217134310U (en) * | 2021-12-31 | 2022-08-05 | 常熟开关制造有限公司(原常熟开关厂） | Thermal overload release of circuit breaker |
| CN217182116U (en) * | 2022-05-05 | 2022-08-12 | 温州宏丰特种材料有限公司 | Copper-aluminum composite connecting assembly of molded case circuit breaker |
| CN115440543A (en) * | 2022-09-16 | 2022-12-06 | 温州宏丰电工合金股份有限公司 | Electric leakage circuit breaker conductor assembly and preparation method thereof |
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